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IS 4631 (1986) : Code of practice for laying of epoxy resin
floor toppings [CED 5: Flooring^ Wall Finishing and
Roofing]

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PROTECTED BY COPYRIGHT

I5:4e3t - 1386

( Reaffirmed 2001 )

Indian Standard

CODE OF PRACTICE FOR
LAYING OF EPOXY RESIN FLOOR TOPPINGS

f First Revision )

UDC 692-535-6: 693-73

® C^ flight I9fl6

INPIAN STANDARDS INSTITUTION
MANAK SHAVAN. 5 BAHA15UR SHAH £AFAR MARO

NEW DELHI nOOCK2

Or 3 Septtmbif 19B6

IS : 4631 - 1986

Indian Standard

CODE OF PRACTICE FOR
LAYING OF EPOXY RESIN FLOOR TOPPINGS

(First Revision)

Flooring and Plastering Sectional Committee, BDC 5

Chairman

Shui O. p. Mittal

S-252, Panchsila Park

New Delhi

Members Representing

Shbi S. K. Banerjee National Test House, Calcutta

Shri D, K. KANUNao ( Alternate )
Shui Dinesh A. Chokshi Arcoy Industries, Ahmadabad

Shri Monal D. Chokshi ( Alternate )
Shbi J. A. D.' Costa Indian Institute of Architects, Bombay

Shbi S. B. Shiromanv ( Alternate )
Deputy Dibect ( Arch ) Ministry of Railways ( Railway Board )

Deptjtyb Diobector ( B&S ) I ( Alternate )
Director Maharashtra Engineering Research Institute, Nasik

Research Officer ( Alternate )
Shbi K. V. Gcbuswamy Indian Oil Corporation Ltd, New Delhi

Shbi G. V. Pakqabkar ( Alternate )
Dr V. S. Gupta The Fertilizer ( Planning & Development ) India

Ltd, Sindri
Brig D. R. Kathuria The Institution of Engineers ( India ), Calcutta

Shbi S, C, Kapoob Modern Tiles & JMarble, New Delhi

Shbi A. G. Kapoor ( Alternate )
Shri K. E. S. Mant Bhor Industries Ltd, Bombay

Shri Ramesh D. Patel ( Alternate )
Shbi M. V. MurugappaK Coromandel Prodorite Pvt Ltd, Madras

Shbi R. Sbinivasan ( Alternate )
Dr Mohan Rai Central Building Research Institute ( CSIR ),

Roorkee

Dr R. K. Jain ( Alternate )
Shbi O. P. Ratba National Buildings Organization, New Delhi

Shbi J. K. K. Singhania Engineer-in-Chief 's Branch ( Ministry of Defence ),

Army Headquarters, New Delhi

Maj S. p. Shabma ( Alternate )

( Continued on page 2 )

INDIAN STANDARDS INSTITUTION

This publication is protected under the Indian Copyright Act ^{ XIV of 1957) and
reproduction in whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.

IS : 4631 - 1986

{ Continued from page 1 )

Members Representing

Superintending Engineer Public Works Department, Government of Tamil

Nadu, Madras
Executive Enginker ( Alternate )
Superintending Surveyor op Central Public Works Department, New Delhi
Works ( GZ )
Surveyor of Works ( CZ ) ( Alternate )
Shri p. N. Talwak Builder's Association of India, Bombay

Shri G. Raman, Director General, ISI ( Ex-officio Member )

Director ( Civ Engg )

Secretary

Shri A. K. Avasthy
Deputy Director ( Civ Engg ), ISI

Acid Resisting Flooring and Cement Materials Subcommittee,

BDC 5 : 6

Convener
Dr V. S. Gupta Fertilizer ( Planning & Development ) India Ltd,

Sindri

Members
Shri H. D. Sarkar ( Alternate to
Dr V. S. Gupta)
Dr p. S. Agarwal Central Glass and Ceramic Research Institute

(CSIR), Calcutta
Dr L. K. Behl Indian Drugs & Pharmaceuticals Ltd, New Delhi

Shri B. N. Chakraverty ( Alternate )
Shri Diistesh A. Chokshi Arcoy Industries, Ahmadabad

Dr K. G. Shah ( Alternate )
Shri C. K. Dhanuka Bombay Potteries & Tiles Ltd, Bombay

Shri P, R. Dubhasi ( Alternate )
Shri Achyut A. Gantule Parshuram Pottery Works Co Ltd, Morvi

Shri G. K. Sheth ( Alternate )
Dr R. B. Hajela Central Building Research Institute ( CSIR ) ,

Roorkee
Shri A. K. Mithgk Directorate General of Posts & Telegraphs, New

Delhi
Shri M. V. Murugappax Coromandel Prodorite Pvt Ltd, Madras

Shri R. SrinivasaN ( Alternate )
Shri M. G. Nair Perfect Potteries ( MB ) Ltd, Jabalpur

Shri G, C. Oswal ( Alternate )
Dr T. V. Prasad Engineers India Ltd, New Delhi

Shri R. S. Ramasubramania Hindustan Ciba-Geigy Ltd, Bombay

Dr H. a. Monteire ( Alternate ) ^ r t, v

ShbiH. S. Satyanarayana Ministry of Defence ( Engineers-in-Chief's Branch ),

Army Headquarters, New Delhi
Shri B. K. Sharma ( Alternate )
Dr G. D. SmoH Kumardhubi Fireclay and Silica Works Ltd,

Kumardhubi

IS : 4631 * 1986

Indian Standard

CODE OF PRACTICE FOR
LAYING OF EPOXY RESIN FLOOR TOPPINGS

(First Revision)

0. FOREWORD

0.1 This Indian Standard ( First Revision ) was adopted by the Indian
Standards Institution on 31 January 1986, after the draft finalized by the
Flooring and Plastering Sectional Committee had been approved by the
Civil Engineering Division Council.

0.2 Epoxy resins are steadily finding increased use in the building industry
on account of their qualities of adhesion and chemical resistance. They
are suitable for use on industrial floors, such as in chemical plants
manufacturing fertilizers, pharmaceuticals, acids and solvents, in dairies,
tanneries, breweries, garages, service stations, warehouses, metal plating
and pickling areas. The use of epoxy resin for industrial floor topping
is characterized by its exceptional physical and chemical properties, such
as chemical resistance, hardness, abrasion resistance, compressive, impact
and flexural strengths, negligible shrinkage, dimensional stability and
adhesion to cured concrete, metals and other surfaces.

0.3 As the mechanical and the chemical properties of the epoxy resin
floor topping mix depends on the composition of the mix, it is essential
that the formulator should be consulted for details concerning the material.
This standard first published in 1968, was intended to give detailed
guidance to the user, engineer, and architect in the method of laying an
epoxy resin f^oor topping and the precautions that are to be taken in
handling this material. In this revision, the specification for epoxy resins
and epoxy resin compositions for floor topping have been given in accord-
ance with IS : 9197-1979*. Where a heavily filled travelHng compound
is applied, recommendations for applying seal coat of unfinished resin
have been included.

0,4 Methods of tests in epoxy resins compositions shall be done in accord-
ance with IS : 9162-1979t.

*Specification for epoxy resin, hardnera and epoxy resin compositions for floor
topping.

fMethods of tests for epoxy resins, hardners and epoxy resin compositions for floor
topping.

IS : 4631 " 1986

0.5 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, ex-
pressing the result of a test or analysis, shall be rounded off in accordance
with IS : 2-1960*. The number of significant places retained in the
rounded ofiT value should be the same as that of the specified value in
this standard.

i. SCOPE

1.1 This standard deals with the method of laying epoxy resin of joint-
less floor toppings and the precautions to betaken in laying them.

2. TERMINOLOGY

2U> For the purpose of this standard, the following definitions shall apply.

2.1 Plasticizer — A compound which, when added to an epoxy resin
hardener mixture, will not enter into the curing reaction, but at the same
time will improve the resilience and toughness of the cured resin and
thereby also its thermal shock resistance, impact resistance, peel strength
and flexibility.

2.2 Flexibilizer — A compound which will take part in the curing
reaction of an epoxy resin and improve the resilience and toughness of
the cured resin thereby also its thermal shock resistance, impact resist-
ance, peel strength and flexibility,

2.3 Amine-Adduct — An addition product of an amine with an epoxy
compound which is used as a curing agent for epoxy resins,

2.4 Pot-Life — The time taken after addition of the hardener for a resin
to reach an unusable state and -is greatly influenced by prevailing tem-
perature.

3. MATERIALS

3.0 An epoxy resin floor topping shall consist essentially of the materials
given in 3.1 to 3.6.

3.1 Epoxy Resin — Epoxy resin shall conform to IS : 9197-1979t.

3.2 Hardeners — Hardeners shall conform to IS : 9197-1979t.
3-3 Accelerator — Accelerator shall conform to IS : 9197-19791.

*iluies for rounding off numerical vaiues ( revised),

tSpecification for epoxy resins, hardeners and epoxy resin composition for floor
topping.

IS : 4631 - 1986

3.4 Plasticizers and Non-Reactive Diluents — Plasticizers and non-
reactive diluents shall conform to IS : 9197-1979*.

3.5 Liquid Coal Tar — Liquid coal tar shall conform to IS : 9197-
1979*.

3.6 Aggregates — Aggregates ^hall conform to IS : 9197-1979*.

4. PROPERTIES OF EFOXY RESIN COMPOSITION

4.1 The properties of epoxy resin composition shall conform, to IS : 9197-
1979*.

5. TYPES OF EPOXY RESIN TOPPINGS

5.0 There are basically two types of epoxy resin floor toppings commonly
available in addition to special finishes, each of which is designed for a
specific class of floor requirements,

5.1 Trowel Type — This is usually heavily filled with sand or other
suitable aggregate and the compound is applied by trowel. Such com-
pounds are often referred to as mortars or screeds.

5.2 Flow Type — This is usually a solventless compound containing
filler and pigment and the mixture is poured directly on to the surface
when the blend will flow and level itself often with little assistance to form
a smooth continuous coating.

5.3 Terrazzo Floors — The Portland cement in the conventional ter-
razzo floors is replaced by epoxy resin binder. Such flooring formulations
serve the dual purpose of providing a good appearance and chemical
resistance,

5.4 Non-Skid Floors — This type of floor may be prepared by sprink-
ling a suitable grit on an epoxy resin floor topping when the latter is still
in a tacky state.

6. RECOMMENDED THICKNESS

6.1 The following minim.um. thicknesses of epoxy resin floor toppings are
recommended to obtain satisfactory performance:

a) Trowel Type — 4 mm for normal use and 6'5 mm in areas of
thermal shock and heavy traffic on horizontal surfaces,

b) Flow Type — 2 mm, and

c) Terrazzo Floors — 10 mm.

♦Specification for epoxy resins, hardeners and epoxy resin composition for floor
topping.

IS : 4631 - 1986

7. EQjUiPMENT

7.1 fixing — The resin and the hardener (constituents shall be blended
just before use by suitable means. Power mixing with good shearing
action may be adopted. For small jobs, hand mixing may be done with
trowels taking special care that the resin does not come into contact with
the skin of the workman. In the case of flow-type floor mix, the use of
a continuous mixing equipment with predeterm.ined ratios for the cons-
tituents may be permitted.

7.2 Spreading — Conventional types of spreading equipment, including
trowels, notched spreaders and screed levelling devices, may be used.
Water or detergent solutions to wet the trowel for easier trowelling shall
not be used. As epoxy resins are sensitive to moisture due care shall
be taken that equipment for mixing and application shall not be in wet
condition when brought in contact with the resin.

8. PREPARATION OF FLOOR SURFACE

8.1 To ensure proper adhesion of the epoxy resin mix, the substrate shall
be clean, free from grease and oil, dry and rough.

8.2 Goiacrete Surface — Before application of the epoxy resin topping,
the base concrete floor shall be properly cured and dried and kept rough
at the time of application of the epoxy resin topping. Laitance shall
be removed from the concrete surface by washing the floor with dilute
hydrochloric acid. Sand blasting or hacking may be adopted for rough-
ening the concrete surface, in the case of an already existing concrete
floor, the structural soundness of the concrete surface shall be examined
before the epoxy resin topping is applied. All the cracks and broken
areas on an existing concrete base shall be sealed, fresh concrete shall be
laid and the portion shall be completely cured before the application of
epoxy resin topping. Heavy contamination on an existing concrete floor
shall be removed by scarification or wire brushing if required. Grease
and oil shall be removed by washing the surface with solvents, such as
acetone or a suitable detergent. For cleaning of the base concrete sur-
face, a dilute hydrochloric acid solution ( 10 to 15 percent ) shall be
poured and allowed to react with the concrete surface for about 15
minutes till no more bubbling is visible on the surface. The resulting
slush shall be thoroughly rinsed with plenty of water or dilate ammonia
solution and tested with litmus paper. The surface shall then be allowed
to dry,

8.2.1 An even concrete surface is very essential as otherwise excess
quantity of costly epoxy materials would be consumed in filling the
surface.

IS : 4631 - 1986

8,3 Mild Steel or Cast Iron Surfaces — The surface shall be washed
with a suitable solvent or detergent solution to remove any grease or oil.
The surface shall then be sand-blasted or abraided with emery cloth,
abrasive disc or with wire brushes.

9, LAYING

9.1 Mixing of Epoxy Resin Blend — The mixing shall be carried out
at the site as follows:

a) The constituents required for the particular epoxy resin topping
shall be mixed in the correct proportions specified by the for-
mulator.

b) In mixing the blend, unless otherwia^e specified by the formulatorj
the order of addition of the components to the equipment shall
be resin, hardener and aggregate ( where separate or additional
aggregate is required for the blend ).

c) Aggregates, where used, shall be added to the blend in the mixer
in a dry condition. Supplies of aggregate should, therefore, be
delivered and stored to maintain suitable dry conditions.

d) The duration of mixing of the separate components of the epoxy
resin blend shall be adequate to ensure thorough mixing and the
quantity of resin mixed at any one time shall be such that the
mix can be applied and spread within the known pot-life.

9.2 Application — Application of the epoxy resin topping shall be done
in accordance with the procedure laid down in 9.2.1 and 9.2.2.

9.2.1 The blended epoxy resin mix shall be applied and uniformly
spread over the prepared area to give the required thickness. It is
recommended that the floor area be laid out in sections so that a uniform
thickness of epoxy resin topping may be applied over the whole floor.

9.2.2 For some areas where a heavily filled trowelling compound is to
be applied, the prepared area shall be first covered with a tack coat of
the unfilled resin-hardener mix applied by brush and this shall be
allowed to cure partly to a tacky stage before the actual topping is
applied,

9.2.2.1 Where a heavily filled trowelling compound is used, it is
advisable to apply a seal coat of unfinished resin to ensure that pores, if
any, are sealed adequately.

9.2.3 Tools — As mild steel tools are liable to cause stains on light
coloured surfaces, it is recommended that stainless steel, chromium
plated steel or rigid PVG tools should be used for laying of epoxy resin
floor toppings.

IS : 4631 - 1986

9.3 Setting of Floor Topping Before Use — After application of the
epoxy resin topping, the floor shall be allowed to set without disturbance
for a minimum period of 24 hours. The floor can be brought to Jiormal
use after a minimum period of 7 days at temperature of 20°C and above,
though light traffic may be permitted after 24 hours of laying the floor
topping. Below 20*'C special hardeners may be used as recommended
by the formulator in order to obtain proper setting of the floor topping.

9.4 Expansion Joints — The expansion joints to coincide with the
expansion joints in the base concrete should be provided in epoxy top-
pings. The expansion joints for the epoxy topping should be filled with
a flexible putty that shows appropriate water and chemical resistance.
The formulators should be consulted for a suitable material.

10. SAFETY PRECAUTIONS

10.1 Epoxy resins may cause irritation to persons having sensitive skin.
Providing good ventilation of the work rooms and storage rooms, main-
taining cleanliness at work and in work -clothing, and talcing maximum
care when processing resins and hardeners arexecommended to minimize
these hazards. The most effective precaution is the use of rubber or
polyethylene gloves. It is preferable to wear thin cotton gloves
underneath for comfort covered by rubber or polyethylene. Other
measures recommended for individual workers are regular washing of
hands, arms and face with soap and lukewarm water, followed by thorough
drying with a clean towel, and the use of a good barrier cream.
Splashes on the skin should be removed immediately by washing with
soap and lukewarm water. On no account should a solvent be used for
the purpose. In mild cases of skin irritation the symptoms generally
disappear within a few days and in doubtful cases, a doctor should be
consulted.

11. CHEMICAL RESISTANCE

11.1 A general guide for chemical resistance of epoxy resin flooring
mixes to various substances is given in Table 1. Table 1 shows that
systems cured with amines exhibit higher chemical resistance. Polya-
mide hardeners should be used where floors are exposed to frequent
impact stress and fluctuations in temperature. The performance of floor
will, however, depend on whether it is exposed to different chemicals,
chemicals of different concentrations and whether chemical and mechani-
cal stresses occur simultaneously. Variations in temperature would also
affect the performance of the floor topping.

12. MAINTENANCE

12.1 Very little maintenance is required for epoxy resin floor toppings.
However, the following precautions would prolong the service life of the
topping.

IS : 4631 • 1986

TABLE 1 CHEMICAL RESISTANCE OF EPOXY RESIN

FLOORING MIXES

(ClavseWA )

Substance

Chemical Resistance at 20'G

Compounds Cured with

Amine or Amine-Adduct

Polyamide

Hardeners

.A..

f ' ■ "
E

p '

Acetic acid, 5 percent

— .

—

Acetic acid, lOpercent

„

—

Acetic acid, 50 percent

- —

—

Acetic acid, anhydride

—

Ammonium hydroxide, 10 percent

—

— -

—

„-

—

Ammonium hydroxide, 30 percent

—

Alchols ( ethyl alchols )

' — .

—

• — •

—

Aliphatic hydrocarbons ( naphtha )

■"-

—

Aromatic hydrocarbons ( toluene )

—

— .

— ■

■ —

—

Beer

—

Blood

—

— .

Boric acid

—

Calcium chloride, 50 percent

—

solution

Caustic soda, 10 percent

■ —

—

Caustic soda, 50 percent

—

— .

' —

—

Chlorinated hydrocarbons ( carbon

—

tetrachloride )

Citric acid, 10 percent

—

— .

—

Cooking fats and oils

■ —

—

Ester

—

— .

—

Ether ( ethyl ether )

—

Fats and oils

—

Formaldehyde, 37 percent

—

Glycerine

—

. — .

■ —

—

Hydrochloric acid, 10 percent

—

Hydrochloric acid, 37 percent

—

Javel water

—

■ — ■

—

— ■

—

Ketone ( acetone )

—

■ — '

—

Lactic acid, 10 percent

■ —

—

■ —

—

Liquid fuel ( petrol or oil )

—

• —

—

Milk, sour or fresh

—

■ —

—

Nitric acid, 10 percent

—

Nitric acid, 50 percent

—

• —

. —

—

Soapsand detergents

—

Sugar ( saturated solution )

—

■ —

' —

—

Sulphuric acid, 10 percent

—

Sulphuric acid, 50 percent

—

Tap water

—

—^

—

— .

—

Urine

—

Vegetable oils

—

Water ( distilled )

—

• —

—

Note — E ^ excellent, G = good, S

= satisfactory, and P =

poor.

IS : 4631 - 1986

12.1.1 For cleaning of the floor, usual household detergents, soap and
warm water ( up to 60°G ) maybe used in conjunction with mopping,
but stubborn dirt marks may require scrubbing. Use of powerful oxidiz-
ing agents should, however, be avoided.

12*1.2 Epoxy resin floor toppings tend to develop cracks when subjected
to quick thermal cycles. Hence frequent alternate quick hot and cold
water hosing should be avoided.

12.1.3 Dragging of heavy sharp edged loads should be avoided since
the flooring would be liable to scoring.

12.1.4 Spillages of powerful solvents like acetone and trichloroethylene
should be drained away as quickly as possible.

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Full text of "IS 4631: Code of practice for laying of epoxy resin floor toppings"

See other formats